Download Batch Chemical Process Fingerprint

Process Automation › Advanced Services
Batch Chemical Process Optimization
Identify opportunities for batch process improvement
Typical issues facing batch processes
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Long batch cycle times
Process bottlenecks limiting production
Reactor problems resulting in low yields
Poor product quality
Poor control performance causing long periods of off spec
production
Plants with batch operations can benefit from this platformindependent, non-invasive service. The service includes an
improvement plan with site-specific improvement opportunities,
prioritized by estimated economic benefit.
Solution
The Batch Process Optimization diagnostic service assesses
the current performance of a batch process area to establish a
“fingerprint”, a unique performance benchmark. This includes
a statistical analysis of process instrumentation data and
laboratory data to provide an assessment of batch cycle
times as well as cycle times for individual steps and phases.
It also includes an evaluation of instrumentation and control
loop performance. A resulting report provides improvement
recommendations.
Benefits
−− Facilitates management decision process by focusing on high
value opportunities for improvement
−− Reduce variability between batches
−− Increase yield, reduce waste / off spec production
−− Reduce batch cycle time to increase productivity
−− Reduce total operating costs.
−− Clear path to quickly close the performance gaps by using
the proposed improvement plan
Features
−− Access to ABB optimization experts
−− Batch Performance Benchmarking
−− Detailed improvement plan
The Batch Process ‘fingerprint’
service typically reveals
opportunities to save $100,000 to
$250,000 annually in energy and
raw material costs
The ABB Batch Process Fingerprint identifies and documents
opportunities for batch process improvements. Batch cycle
times, step and phase cycle times, and instrumentation and
control loop performance are used to define benchmarks for
batch performance.
Performance Indicators
Comprehensive testing and analysis will measure Key
Performance Indicators, used to assess batch performance and
improvement area potential:
− − Batch Cycle Times
− − Step and Phase Cycle Times
− − Instrumentation and Control Loop Performance
Process Analysis
Each performance indicator includes indices derived from
historical batch data collected over a specific time period. The
indices are used to evaluate the performance level of various
aspects of the batch process, including but not limited to:
− − Level 1 controls
−− Flow, pressure, level, and temperature controllers at
different production rates
− − Level 2 supervisory controls
−− Composition and temperature profiles, satisfaction of
product specifications
−− Critical product specification limits
−− Operating constraints
−− Batch control configurations
Identifying the process area(s) that are under-performing is the
first objective in the diagnostic procedure. The robustness of
the diagnostic has a significant impact on the efficiency and
consistency with which the improvements can be achieved. In
order to provide practical solutions for problems often identified
in a batch process, ABB has developed well-defined, logical
optimization procedures.
The process and lab data is analyzed to provide the resulting
Key Performance Indicators. Data from multiple batches can be
trended together and KPIs compared. The trends allow for fast
visualization of batch data with the ability to zoom in on periods
of interest.
Improvement Plan
The improvement plan defines how to resolve the performance
bottlenecks and how to move toward optimal performance.
In addition, the associated financial impact for each
recommendation is provided.
Based upon the findings, recommendations may include but
are not limited to tuning PID controls, adjusting supervisory
controls, adding optimizing controls, modifying base control
logic, editing recipes and updating batch procedures for
operations.
Additional ABB Process Optimization Services
The Batch Process Fingerprint Service is the first step in
achieving and sustaining higher performance levels. ABB
offers Performance Improvement Services and Performance
Monitoring Services to complete the continuous improvement
cycle.
Performance Improvement Service
ABB offers this service to implement the improvement plan
outlined in the Batch Process Fingerprint report. An ABB
Engineer, experienced in batch process controls and process
improvement, is assigned to lead the improvement activities.
Other ABB Services
− − Advanced Process Control
− − Alarm Management Fingerprint
− − Industrial Boiler Fingerprint
− − DCS Diagnostic Fingerprint
− − Cyber Security Fingerprint
The batch data analysis helps to identify bottlenecks that limit
cycle times. Recommendations help to increase uptime, reduce
response times to upsets, and Increase throughput. The results
also help to reduce the time needed to investigate quality and
equipment issues.
Reporting
A report is provided to disclose the findings and
recommendations of the process performance diagnosis. This
includes an actionable improvement plan.
North America Customer Contact Center
29801 Euclid Avenue, Wickliffe OH 44092, USA
Tel:
1 800 HELP 365 (1 800 435 7365)
Outside USA/Canada: +1 440 585 7804
E-mail:[email protected]
Web: abb.com/processautomation
© 2015 ABB Inc. ABB reserves the right to change specifications without notice.
3BUS095870
Batch Process Fingerprint
Identify opportunities for batch process improvement